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The electric induction furnace is a type of melting furnace that uses electric currents to melt
metal. Induction furnaces are ideal for melting and alloying a wide variety of metals with
minimum melt losses, however, little refining of the metal is possible.
The principle of induction heating is mainly based on two well-known physical phenomena:
1. Electromagnetic induction
2. The Joule effect
1) ELECTROMAGNETIC INDUCTION
The energy transfer to the object to be heated occurs by means of electromagnetic induction.
Any electrically conductive material placed in a variable magnetic field is the site of induced
electric currents, called eddy currents, which will eventually lead to joule heating.
2) JOULE HEATING
Joule heating, also known as ohmic heating and resistive heating, is the process by which
the passage of an electric current through a conductor releases heat.
The heat produced is proportional to the square of the current multiplied by the electrical
resistance of the wire.
Induction heating relies on the unique characteristics of radio frequency (RF) energy
- that portion of the electromagnetic spectrum below infrared and microwave energy.
Since heat is transferred to the product via electromagnetic waves, the part never
comes into direct contact with any flame, the inductor itself does not get hot and there
is no product contamination.
The induction coil is cool to the touch; the heat that builds up in the coil is constantly
cooled with circulating water.
An electric induction furnace requires an electric coil to produce the charge. This
heating coil is eventually replaced.
The crucible in which the metal is placed is made of stronger materials that can resist
the required heat, and the electric coil itself cooled by a water system so that it does
not overheat or melt.
The induction furnace can range in size, from a small furnace used for very precise
alloys only about a kilogram in weight to a much larger furnaces made to mass
produce clean metal for many different applications.
foundries use this type of furnace and now also more iron foundries are replacing
cupolas with induction furnaces to melt cast iron, as the former emit lots of dust and
other pollutants.
Induction furnace capacities range from less than one kilogram to one hundred tonnes
capacity, and are used to melt iron and steel, copper, aluminium, and precious metals.
The one major drawback to induction furnace usage in a foundry is the lack of refining
capacity; charge materials must be clean of oxidation products and of a known
composition, and some alloying elements may be lost due to oxidation (and must be
re-added to the melt).
There are many different designs for the electric induction furnace, but they all center
around a basic idea.
The electrical coil is placed around or inside of the crucible, which holds the metal to
be melted. Often this crucible is divided into two different parts. The lower section
holds the melt in its purest form, the metal as the manufacturers desire it, while the
higher section is used to remove the slag, or the contaminants that rise to the surface of
the melt.
Crucibles may also be equipped with strong lids to lessen how much air has access to
the melting metal until it is poured out, making a purer melt.
TYPES OF INDUCTION FURNACE
There are two main types of induction furnace: coreless and channel.
Induction furnaces offer certain advantages over other furnace systems. They include:
Higher Yield. The absence of combustion sources reduces oxidation losses that can be
significant in production economics.
Faster Startup. Full power from the power supply is available, instantaneously, thus
reducing the time to reach working temperature. Cold charge-to-tap times of one to two
hours are common.
Natural Stirring. Medium frequency units can give a strong stirring action resulting in a
homogeneous melt.
Compact Installation. High melting rates can be obtained from small furnaces.
Reduced Refractory. The compact size in relation to melting rate means induction furnaces
require much less refractory than fuel-fired units
Better Working Environment. Induction furnaces are much quieter than gas furnaces, arc
furnaces, or cupolas. No combustion gas is present and waste heat is minimized.
Surprise Quiz:
1) Which one of the following is the best option for quick melting of scrap.
Cupola furnace Electric arc furnace
Induction furnace Blast furnace